JPS6224268B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight inorganic decorative foamed body. Specifically, the present invention relates to a lightweight inorganic decorative foam in which an inorganic foam material is foamed and at least one surface of the inorganic decorative material is fused and integrated, and a method for producing the same.

Conventionally, this type of inorganic decorative foam has been produced by first producing a lightweight inorganic foam, and then (i) applying a glaze or the like to the surface of the foam and applying a decorative finish by firing or spraying. or (ii) it has been manufactured by applying a decorative material such as a tile to the surface of the foam using an adhesive to give it a decorative finish. In addition to the two-step firing process for the decorative foam (i) above,
It is quite difficult to sufficiently decorate the rough surface of a foam with a glaze, and when a primer is used in combination with a glaze, there is a risk that the glaze is likely to peel off. In the case of the above-mentioned decorative foam (ii), in addition to being labor-intensive in construction, there is a limit to the heat-resistant adhesive properties, regardless of whether an inorganic adhesive (for example, cement) or an organic adhesive is used. As a method to simplify these processes, a decorative plate has been developed and proposed in which a hard urethane foam layer is foam-adhered to the back side of the decorative material using urethane resin material as the foam material (Special Publications Publication No. 1973).
−30138). However, this product naturally has problems with strength and adhesion at elevated temperatures due to its organic material. Furthermore, there are problems with the generation of toxic gases during production and water absorption due to open cells.

Regarding the embodiment of the present invention in which a decorative material such as a tile is fused at the same time as the inorganic material is foamed, under firing conditions that sufficiently foam the inorganic material without thermally denaturing the decorative material, there is sufficient strength between the two. It appears that some fused integration was previously thought to be unattainable.
By combining a decorative material having a back surface made of a silicate-based material and a silicate-based foam material that melts to form a glassy substance, the present inventors unexpectedly achieved both foaming and simultaneous foaming. It has been found that satisfactory fusion between the two can be achieved.

That is, according to the present invention, a surface material made of a decorative material having a back surface of a silicate material is integrated with a vitreous fusion on at least one surface of a base material of a vitreous silicate foam. A lightweight inorganic decorative material fused foam body useful as a building material etc. is provided.

The above-mentioned decorative material fusion-bonded foam lightweight body has the back side of the surface material made of the above-mentioned decorative material on at least one frame surface (i.e., one or more surfaces) of the frame surface of the firing frame (for example, a sagger). The system is heated to a temperature below the thermal denaturation of the decorative material and melting of the foam material. It can be effectively manufactured by a manufacturing method characterized in that the material is melted and foamed by firing at a temperature higher than the foaming temperature, and at the same time the two are fused.

In this manufacturing method, at least the back surface of the decorative material and the foam material are silicate-based materials, and upon firing, the foam material melts and wets the contact surfaces of the two, and both are silicate-based materials. Due to system assimilation, the melted material solidifies as it cools, achieving a strong fusion bond between the two. In the above manufacturing method, although it is generally not necessary, a vitreous forming material or a fused material that does not contain a blowing agent and is substantially the same as the foam material is added to the contact interface between the decorative material and the foam material. When a small amount of a glass-based material with high adhesion is present, the fusion bond between the two is further enhanced.

The above-mentioned glass-forming silicate-based foam material is a powder or granular material containing a powder of a silicate-based material that can be melted to form a glassy substance and an effective amount of a powdered blowing agent that releases gas when heated and fired. It is a silicate-based material.

Examples of the glass-forming silicates include anti-flinder (scientific name: glass mica trachyte), volcanic ash (for example, shirasu), glassy waste materials, expanded shale, perlite, slag, and mixtures thereof. The blowing agents include, for example, silicon carbide, silicon nitride, carbon, water glass, gypsum, carbonates, and mixtures thereof. The foaming agent has desired insulation performance,
Although it varies depending on the required performance such as bulk specific gravity and the foaming components, in the present invention, the foam material is approximately
0.1 to about 2%, preferably about 0.3 to about 1.5% and typically around about 0.5 to about 1% can be used.

The above-mentioned foam material can be easily selected by those skilled in the art from the viewpoint of the silicate material and the physical properties of the foam. For example, in a material whose main component is anti-flinder and/or volcanic ash, silicon carbide is preferred from the viewpoint of forming closed cells and controlling sinterability, melt viscosity, amount of gas generated, and the like.

In addition to the glass-forming silicate material and blowing agent, the silicate foam material includes an amount of mudstone (shale) in an amount less than about 40% by weight of the material to control and adjust the foaming conditions. , claystone, siltstone, etc.) and typically shale, kaolin, silica sand, etc. can be advantageously used.

The decorative material used as the surface material is selected from inorganic decorative materials whose back surface is made of a silicate material, and typical examples include glazed ceramic tiles and stone. In the case of glazed tiles, it is preferable that the glaze be one that melts at high temperatures. In other words, if the surface material is a heat-resistant plate whose back surface is made of a silicate-based material, the silicate-based foam material is melted and foamed to create a glassy fusion between the two. Not limited. Examples of such ceramic tiles include ceramic, mortise or porcelain tiles, and in the case of mortise tiles, large lamellar tiles are known. For example, as such stone-based surface materials, natural stone plates such as basalt plates and artificial stone plates such as concrete plates or glazed concrete plates are known in the industry.

The firing conditions for the foam fusion described above may vary depending on the material, but generally include a firing temperature of about 800°C to about 1300°C and a firing time of about 0.5 hours or more (for example, about 1 to about 8 hours). range. That is, the above firing conditions can vary depending on the desired foaming properties (cell shape, heat insulation, etc.) in addition to the materials used.
For example, those skilled in the art can easily set the conditions based on typical conditions of about 900° C. to about 1200° C. for about 2 hours or more.

As mentioned above, the decorative material is arranged in a frame such as a sagger and filled with the foam material. It is common to fill the container with materials (if necessary, place a decorative material face down on top of the filled materials), then cover with a lid of an appropriate weight and fire. Naturally, it is also possible to adopt a vertical frame, affix a decorative material to one or both sides thereof, fill it with foam material, cover it, and then fire it. It is preferable to sprinkle or adhere a refractory powder such as alumina on the surface of the frame on which the decorative material is placed to prevent welding and temporary overheating. In addition, by placing the decorative material on both the upper and lower surfaces or both sides of the frame, a product having the decorative material fused to both surfaces of the foam can be obtained. Although this is useful in itself, it is also possible to cut the foam parallel to the face of the decorative material to obtain a foam with the decorative material fused to one side.

Typical embodiments of the present invention are illustrated below,
The present invention will be further explained. However, it is understood that the present invention is not limited to these examples, and that variations and modifications within the technical idea of the present invention are naturally possible.

Example 1 Granulated powder anti-flinder stone 100 as a foam material
parts by weight, 1 part by weight of silicon carbide powder and 10 parts by weight of shale powder
A homogeneous mixture powder consisting of parts by weight was used. Sprinkle alumina powder on the bottom of a sagger pot with internal dimensions of 200 x 200 mm, place glazed ceramic tiles (total weight 600 grams) with the back side of the tiles facing upward, and sprinkle the above mixed powder on top of it to a thickness of 25 mm. was filled.
This was fired at 1150°C for 4 hours and left to cool. In this way, a plate-shaped foamed lightweight body that was fused and integrated with the decorative tile surface material was obtained by achieving foaming and fusion at the same time. The thickness of the lightweight foam base material is 55 mm and the weight is 550 grams,
Therefore, the specific gravity was 0.42. Furthermore, the resulting foam was substantially non-water-absorbing and consisted essentially of closed cells.

Example 2 As a material for a foam, a mixed powder consisting of 100 parts by weight of anti-flame rock, 1 part by weight of silicon carbide, and 75 parts by weight of PVA was made into small particles using water. In the same manner as in Example 1, basalt pieces cut into flat plates were placed in a sagger pot having the same dimensions as in Example 1, filled with the above foam material, and fired at 1200° C. for 4 hours. By leaving to cool, a plate-shaped glassy foam was obtained which was fused and integrated with the surface material of the basalt decorative material.

Example 3 Firestone is placed between the decorative tile and the foam material.
The same procedure as in Example 1 was carried out except that a mixed powder containing 100 parts by weight of shale and 10 parts by weight of shale, which did not contain a foaming agent, was thinly sprinkled. When the fused portion of the obtained lightweight decorative tile fused foam was inspected, it was found that the state of fusion between the tile and the foam was even more dense.

Claims (1)

[Scope of Claims] 1. Consisting essentially of a base material of a foamed lightweight body made of a silicate-based material capable of forming a vitreous substance, and a surface material of an inorganic decorative material having a back surface made of a silicate-based material, the lightweight A lightweight inorganic decorative material fused foam body characterized by a structure in which the back side of the surface material is vitreously fused and integrated with at least one surface of a body base material. 2. The lightweight body of claim 1, wherein the main component of the material of the foamed lightweight body is selected from anti-flinder, volcanic ash, glass-based materials, expanded shale, nacre, slag, and mixtures thereof. 3. The lightweight body of claim 2, wherein the foamed lightweight body further contains a mudstone-based component. 4. The lightweight body according to claim 1, 2 or 3, wherein the foamed lightweight body contains at least a flint-retardant. 5. The lightweight body according to any one of claims 1 to 4, wherein the foamed lightweight body is substantially composed of closed cells. 6. The lightweight body according to any one of claims 1 to 5, wherein the decorative material is selected from glazed ceramic tiles and stone. 7. A surface material of an inorganic decorative material having a back surface made of a silicate-based material is placed on at least one frame surface of the firing frame with the back surface facing inside, and silicic acid which is a vitreous-forming material is placed on at least one frame surface of the firing frame. A granular material for a salt-based foam is filled into the firing frame in contact with the back side of the silicate-based material of the surface material, and the temperature is below the thermal denaturation of the decorative surface material and the temperature of the material for the foam is lowered. The material for the foam is foamed by firing at a temperature higher than the melting and foaming temperature to form a foamed lightweight body base material, and the silicate-based back surface of the decorative surface material and the surface of the lightweight body in contact therewith. A method for producing a lightweight foamed material fused to an inorganic decorative material, which is characterized by forming a vitreous fused bond between the layers. 8. The method of claim 7, wherein the foam material contains an effective amount of a blowing agent that releases gas upon firing. 9. The method of claim 8, wherein the blowing agent is selected from silicon carbide, silicon nitride, carbon, water glass, gypsum, carbonates, and mixtures thereof. 10. The manufacturing method according to any one of claims 7 to 9, wherein the main component of the foam material is selected from anti-flinder, volcanic ash, glass-based materials, expanded shale, perlite, slag, and mixtures thereof. 11. The method of claim 10, wherein the foam material further contains a mudstone component. 12. The manufacturing method according to any one of claims 7 to 11, wherein the foam material contains at least a flint-resistant stone. 13. The manufacturing method according to any one of claims 7 to 12, wherein the blowing agent contains at least silicon carbide. 14. The manufacturing method according to any one of claims 7 to 13, wherein the decorative material is selected from glazed ceramic tiles and stone.